The electrical properties of copper braided wire are affected by a variety of factors
Material Factors: Copper Purity: The higher the purity of copper, the better the conductivity. If the copper contains impurities such as aluminum, antimony, arsenic, phosphorus, nickel, lead, etc., the resistance of the copper braided wire will increase and reduce its conductivity. For example, the electrical properties of high-purity oxygen-free copper braided wire are better than those of ordinary copper braided wire.
Tin plating quality: Some copper braided wires will be tin plated to enhance oxidation resistance and other properties. The uniformity and thickness of the tin plating layer will affect the electrical properties. If the tin plating layer is uneven or the thickness is insufficient, it may lead to an increase in local resistance and affect the current transmission; A good tin plating layer can reduce the contact resistance to a certain extent and improve the stability of electrical properties.
Braiding process factors: braiding density: the tighter the braiding, the larger the contact area between the copper wires, the more and shorter the transmission path of the current, the smaller the resistance, and the better the electrical performance. On the contrary, the loose braided copper wire has a high resistance, and the conductivity will be affected to a certain extent. For example, in high-voltage electrical equipment with high electrical performance requirements, copper braided wires with a high braided density are used.
Braiding method: Different braiding methods (such as single layer braid, multi-layer braid, etc.) will affect the structural stability and electrical properties of copper braided wire. Multi-layer braided copper braided wire generally has better mechanical strength and electrical properties, but it is also relatively costly. The specific weaving method needs to be selected according to the needs of the actual application scenario.
Monofilament diameter: The copper braided wire made of copper wire with a thick monofilament diameter has a relatively small resistance and can withstand a larger current; The copper braided wire with a thin monofilament diameter has a relatively large resistance, which is suitable for occasions with low current requirements. In some occasions where high current transmission is required, copper braided wire with a thicker monofilament diameter will be selected.
Environmental factors: Temperature: The resistance of copper braided wire will increase with the increase of temperature, which will affect its conductivity. At high temperatures, the current carrying capacity of the copper braided wire decreases and may not be able to meet the normal current transmission needs. Therefore, when used in high-temperature environments, the current carrying capacity of the copper braided wire needs to be derated3.
Humidity: In a high humidity environment, copper braided wire is easy to get wet, and a layer of water film or oxide layer will form on the surface, resulting in increased resistance and decreased electrical performance. If it is exposed to moisture for a long time, it may also cause corrosion of copper braided wire, further impairing its electrical performance.
Chemicals: If the copper braided wire comes into contact with some corrosive chemicals, such as acids, alkalis, salts, etc., a chemical reaction will occur, resulting in corrosion of the copper wire, which will affect its electrical properties and service life.
Connection factors: crimping quality: If the connection between the copper braided wire and other electrical components is crimped, the tightness of the crimping and the contact area of the crimping part will affect the electrical performance. If the crimping is not tight or the contact area is too small, the contact resistance will increase, the heat will increase, and the normal transmission of current will be affected.
Welding quality: For copper braided wires connected by welding, the firmness of the welding, the quality of the welding joints, etc., will also affect the electrical performance. Poor soldering may lead to increased resistance at the solder joint, and even problems such as open circuits.
Tin plating quality: Some copper braided wires will be tin plated to enhance oxidation resistance and other properties. The uniformity and thickness of the tin plating layer will affect the electrical properties. If the tin plating layer is uneven or the thickness is insufficient, it may lead to an increase in local resistance and affect the current transmission; A good tin plating layer can reduce the contact resistance to a certain extent and improve the stability of electrical properties.
Braiding process factors: braiding density: the tighter the braiding, the larger the contact area between the copper wires, the more and shorter the transmission path of the current, the smaller the resistance, and the better the electrical performance. On the contrary, the loose braided copper wire has a high resistance, and the conductivity will be affected to a certain extent. For example, in high-voltage electrical equipment with high electrical performance requirements, copper braided wires with a high braided density are used.
Braiding method: Different braiding methods (such as single layer braid, multi-layer braid, etc.) will affect the structural stability and electrical properties of copper braided wire. Multi-layer braided copper braided wire generally has better mechanical strength and electrical properties, but it is also relatively costly. The specific weaving method needs to be selected according to the needs of the actual application scenario.
Monofilament diameter: The copper braided wire made of copper wire with a thick monofilament diameter has a relatively small resistance and can withstand a larger current; The copper braided wire with a thin monofilament diameter has a relatively large resistance, which is suitable for occasions with low current requirements. In some occasions where high current transmission is required, copper braided wire with a thicker monofilament diameter will be selected.
Environmental factors: Temperature: The resistance of copper braided wire will increase with the increase of temperature, which will affect its conductivity. At high temperatures, the current carrying capacity of the copper braided wire decreases and may not be able to meet the normal current transmission needs. Therefore, when used in high-temperature environments, the current carrying capacity of the copper braided wire needs to be derated3.
Humidity: In a high humidity environment, copper braided wire is easy to get wet, and a layer of water film or oxide layer will form on the surface, resulting in increased resistance and decreased electrical performance. If it is exposed to moisture for a long time, it may also cause corrosion of copper braided wire, further impairing its electrical performance.
Chemicals: If the copper braided wire comes into contact with some corrosive chemicals, such as acids, alkalis, salts, etc., a chemical reaction will occur, resulting in corrosion of the copper wire, which will affect its electrical properties and service life.
Connection factors: crimping quality: If the connection between the copper braided wire and other electrical components is crimped, the tightness of the crimping and the contact area of the crimping part will affect the electrical performance. If the crimping is not tight or the contact area is too small, the contact resistance will increase, the heat will increase, and the normal transmission of current will be affected.
Welding quality: For copper braided wires connected by welding, the firmness of the welding, the quality of the welding joints, etc., will also affect the electrical performance. Poor soldering may lead to increased resistance at the solder joint, and even problems such as open circuits.
